Thermal barrier liner for containers

ABSTRACT

A thermal barrier liner maintains a beverage within a container at a desired temperature. The liner may include a closed cell substrate, a base layer having gas or liquid filled microcapsules, a base layer having microencapsulated solid-liquid phase change material, or combinations thereof. In other embodiments, an integral cooling element incorporates solid/liquid phase change material. The cooling element can either be attached to the exterior of the container, the interior of the container, or free-floating within the container. Other embodiments include container holders or direct beverage holders incorporating phase change materials to control temperature of the beverages. The embodiments may further include thermochromatic ink to provide a visible color indication of temperature changes for the beverage.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation in part application of U.S. patentapplication Ser. No. 12/249,356, filed Oct. 10, 2008 entitled: “ThermalBarrier Liner for Containers,” now U.S. Pat. No. 8,336,729 which claimspriority from the U.S. Provisional Patent Application No. 60/980,127filed on Oct. 15, 2007 and entitled “THERMAL BARRIER LINER FORCONTAINERS,” the disclosures of which are incorporated herein byreference in their entirety.

This application is also a continuation in part application of U.S.patent application Ser. No. 12/249,431 filed Oct. 10, 2008 entitled:“CONTAINER INCORPORATING INTEGRAL COOLING ELEMENT,” now U.S. Pat. No.8,297,072 which claims priority from the U.S. Provisional PatentApplication No. 60/980,197 filed on Oct. 16, 2007 and entitled“CONTAINER INCORPORATING INTEGRAL COOLING ELEMENT,” the disclosures ofwhich are also incorporated herein by reference in their entirety.

FIELD OF THE INVENTION

The present invention relates to a thermal barrier liner for containers,and more particularly, to a thermal barrier liner formed on the innersurface of the container and a method of applying the liner by spraycoating.

BACKGROUND OF THE INVENTION

Portable beverage containers are used to hold many types of beverages toinclude carbonated soft drinks, fruit drinks, and beer. It is well knownto provide a protective internal liner for those containers made ofmetal such as aluminum or steel to help preserve the beverage within thecontainer by preventing undesirable chemical reactions that wouldotherwise take place over time by direct contact of the beverage withthe metallic container. For containers made of plastic, there istypically no internal liner provided because the plastic material isinherently non-reactive with respect to most types of beverages.

Many beverages are preferably consumed at relatively cold temperatures,for example, between about 36° F. and 50° F. For carbonated soft drinksand beer, consumers typically prefer these beverages to be chilled priorto consumption. Traditional chilling or cooling techniques includeplacing the containers in a chilled environment such as a refrigeratoror cooler, and then serving the beverage once the beverage has reached adesired chilled temperature.

When the beverage is removed from the chilled environment, the beveragebegins to quickly warm due to a combination of external heat sourcesincluding ambient heat of the surrounding environment, contact with warmsurfaces such as the consumer's hand or the surface on which thecontainer is placed, as well as radiant heat from the sun or other lightsources. Heat transfer takes place through the walls, base, and top ofthe container to the beverage. Without some means provided forinsulating the container, the beverage so quickly warms that, in manycircumstances, it becomes undesirable or unfit for consumption.

There are a number of inventions that have been developed for purposesof insulating a beverage within the container such that it is maintainedat a desired temperature prior to consumption. For example, it is wellknown to provide external thermal barriers, such as an insulating sleevethat is applied over the exterior sidewall of the container. It is alsoknown to provide an insulated label on the sidewall of the container.There are a number of disadvantages to these traditional methods ofinsulating beverages. An insulating label/sleeve only covers thecontainer sidewall, therefore leaving the bottom of the containerexposed. For insulated labels, they are typically much thicker than anon-insulated label and, therefore, standard packaging line may have tobe substantially modified to accommodate these special labels. Forinsulating sleeves, these require the consumer to maintain a separatecomponent to maintain the beverage at a desired cold temperature.

Some efforts have been made to provide an internal insulating liner forcontainers. One example is disclosed in U.S. Pat. No. 6,474,498. Thisreference discloses a thermally insulated container for canned beveragesincluding a lining formed from a plastics material. The preferredembodiments suggest using a plastic closed cell material to includeclosed cell material similar to bubble wrap. The liner is intended to beplaced into the container as by a slidable fit within the container soas to be in contact with the cylindrical inner surface of the containerwall. The lining member may include an adherent surface allowing thelining to adhere to the internal wall of the container. In analternative embodiment, this reference discloses a closed cell materialthat can be provided as a layer on the interior surface of the metalcontainer in addition to or in place of a conventional lacquered coatingapplied to the interior surface of the container.

U.S. Patent Application Publication No. 2006-0073298 discloses amulti-layer inner liner provided for a container and an extrusion methodfor a beverage container. The method contemplates blow molding the innerliner by co-extrusion of a first inner layer of a thermoplasticsmaterial and a second inner layer made of a foam material havinginsulating properties. The inner layer of foam is further disclosed ashaving micro-spheres that expand during the blow-molding process.

U.S. Patent Application Publication No. 2006-0054622 discloses aninsulated beverage container having an inner liner that adheres to theinside of the container. The inner liner is made from a crystallineceramic material.

In addition to externally mounted sleeves and internal liners, someefforts have also been made to maintain beverages at a desiredtemperature by use of phase change material that is placed within thecontainer. Upon warming, the phase change material changes phase to helpmaintain the beverage at a cooler temperature for a period of time inwhich the consumer would normally consume the beverage.

Phase change materials are substances with a high heat of fusion. Thesematerials are capable of storing or releasing large amounts of energy.Phase change materials used for containers are solid/liquid change phasematerials wherein the phase change material changes phase from solid toliquid at the material's melting point. More specifically, when thebeverage is maintained in a chilled environment below the melting orphase change temperature, the phase change material remains in a solidstate. When the container is removed from the chilled environment duringconsumption of the beverage, the phase change material absorbs arelatively large amount of heat without a significant rise intemperature. Thus, phase change material absorbs heat from thesurrounding beverage in the container thereby keeping the beverage atthe preferred drinking temperature longer.

One reference disclosing use of phase change material in a containerincludes the British Patent GB2370629. A phase change material iscontained in a small chamber such as a tube placed inside the container.The phase change material is activated when the user opens the can. Thephase change material is preferably a liquid, such as water, that boilsor vaporizes in the tube. A lower pressure area or vacuum in the tubeallows the phase change material to vaporize. Upon vaporization, heat istransferred from the beverage to the tube containing the phase changematerial.

International Publication WO9724968 discloses a self-cooling food orbeverage contained in which a phase change capsule, when activated,results in heat exchange contact with the surrounding or adjacent foodor beverage container.

U.S. Patent Application Publication No. 2006/0156756 discloses aself-cooling food or beverage container wherein the container has innerand outer walls and phase change material is located in the spacebetween the walls.

While the foregoing references may be adequate for their intendedpurpose, there is still a need for providing a cooling element that canbe used with a container wherein the cooling element can be easilyincorporated into standard manufacturing and production lines withoutsignificant alteration to these processes. Furthermore, there is still aneed to provide a cooling element for a container wherein the coolingelement can be manufactured and installed at a relatively low cost sothat the ultimate retail price of a container is still competitive withcontainers not incorporating cooling capabilities.

There is also a need for an internal thermal barrier to maintain abeverage at a desired temperature wherein the thermal barrier can beincorporated within a liner applied using standard packaging machinery.Further, there is a need to provide a thermal barrier liner for acontainer wherein the barrier liner can be expanded to cover not onlythe container sidewall, but also the bottom of the container.

SUMMARY OF THE INVENTION

It is one object of the invention to provide a thermally insulatedbeverage container that can effectively and safely keep beverages at adesired temperature during consumption of the beverage.

It is yet another object of the present invention to provide a thermallyinsulated beverage container by providing a thermal barrier linerutilizing a single material that exhibits specific common desirableproperties resulting in creation of an insulated thermal barrier.

It is yet another object of the present invention to provide a uniquecombination of materials that, when combined, exhibit desirable thermalbarrier properties.

It is yet another object of the present invention to provide a method ofinstalling a thermal barrier, such as a spray coated liner.

It is yet another object of the present invention to provide a thermalbarrier that may be applied to different types of beverage containers,such as those made from metal or made from plastic.

It is yet another object of the present invention to provide a thermallyinsulated beverage container that can be introduced into existingbeverage manufacturing, distribution, and sales sectors withoutrequiring significant alterations in manufacturing machinery orprocesses.

It is yet another object of the present invention to provide a beveragecontainer with an integral cooling element that can effectively andsafely maintain a beverage at a desired temperature during consumptionof the beverage.

-   -   It is yet another object of the present invention to provide a        cooling element incorporated within a beverage container wherein        the cooling element can be added to the container without        substantially modifying standard manufacturing and production        processes.    -   It is yet another object of the present invention to provide a        cooling element for a beverage container that may be applied to        many different types of beverage containers, such as those made        from metal or plastic.    -   It is yet another object of the present invention to provide a        cooling element that can be placed within the container having a        relatively small size that takes up a minimum volume within the        container. The cooling element therefore preferably has a        minimum profile that is not intrusive to a user who consumes the        beverage.

In accordance with a first aspect of the present invention, a thermallyinsulated beverage container is provided having a thermal barrier linerformed on the inner surface of the container. The container of thepresent invention may include any known beverage container, such asthose made from aluminum or steel that hold beverages such as beer orcarbonated soft drinks. The container of the present invention mayfurther include known plastic containers, such as PET bottles or cans.

In one embodiment, the thermal barrier liner may include use of a singlematerial having a cell structure comprising a plurality of voids orpockets and wherein the liner covers the interior surface of thecontainer to include the container sidewall and base of the container.In this embodiment, the liner may also be referred to as a closed cellsubstrate layer or foam layer. The material used for the barrier linerin this embodiment has a stretchable or elastic capability such that thevoids may increase in physical size without rupturing. The particularliner material and manner of applying the liner can be selected suchthat the cell sizes create a thermal barrier liner of a desiredthickness when the container is opened. The thickness of the barrierliner as well as the composition of the barrier liner in terms of theamount of void spaces within the liner can also be adjusted to optimizethe thermal barrier liner for purposes of insulating the beverage. Thethermal barrier liner may be made from a cavitated monolayer filmsubstrate containing gas permeable closed cells.

In other embodiments, the thermal barrier liner includes a base materialcontaining encapsulated gases or phase change materials. Theencapsulated gases or phase change materials are dispersed throughoutthe base layer. The base layer is monolithic and the liner is preferablyapplied by spraying as discussed further below.

In yet further embodiments of the present invention, the thermal barrierliner includes a combination of materials that, when combined, exhibitthermal barrier properties. This embodiment may be referred to as acomposite liner including a combination of: (i) a cell structurecomprising a plurality of voids or pockets; (ii) encapsulated gases;and/or (iii) encapsulated phase change materials. In this embodiment,the base material is also preferably applied by spray coating theinterior of the container. One or more spray coating layers can beapplied in a single or multi stage spray application.

In yet another embodiment of the present invention, a thermal barrierliner may be provided in the form of a multi-layer coating constructionwherein voids or gas pockets are found between the layers therebyproviding an effective thermal barrier. In this embodiment, aco-extrusion lamination process can produce the multi-layer coatingwhere portions of adjacent layers are sealed to one another while otherportions are not sealed thus creating the gas pockets or void areasbetween the layers.

In yet another aspect of the present invention, a method is provided forapplying the thermal barrier liner to the interior surface of a beveragecontainer utilizing a spray coating technique and wherein temperature,viscosity, and atomization of the coating may be varied to create adesired thermal barrier liner.

The thermal barrier liner in one of the embodiments is gas permeablethus having the ability to equilibrate with ambient pressure conditions.More specifically, during the application of the liner to the container,the voids or pockets formed in the liner will contain gas of thesurrounding environment, and the ambient pressure will determine thevoid sizes. After the container has been filled and sealed, the interiorof the container develops a higher pressure in which the void areasfurther fill with gas contained in the container, such as carbon dioxideor nitrogen. This gas can reside either in the headspace or can be gasdissolved in the beverage. Since the container is under pressure, thevoids may decrease in size as compared to the size of the voids underambient pressure conditions, however, the voids will contain a greateramount of gas due to the higher pressure conditions in which equilibriumis reached and pressure across the liner is equal. The voids fill withthe gas(es) over a relatively short period of time due to the gaspermeable nature of the liner material.

Once the container is opened, the thermal barrier liner transitions toequilibrium with ambient pressure wherein the pressurized gas containedwithin the voids causes an immediate expansion of the size of the voids.The increased size of the voids creates a thickened liner that is aneffective thermal barrier liner to maintain beverage at a desiredtemperature.

It is also contemplated within the present invention that the thermalbarrier liner can also serve as the standard protective liner used toprevent direct contact between the beverage and the metallic internalsurface of the container. It is also contemplated that the thermalbarrier liner can also be directly applied over a standard protectiveliner, thus not replacing the standard liner.

In another aspect of the invention, a beverage container is providedwith a cooling element that is capable of keeping the container at adesired chilled temperature after the container has been removed from achilled environment. The cooling element makes use of solid/liquid phasechange material contained within an outer protective shell to preventcontact of the phase change material with the beverage within thecontainer. In the chilled environment, the phase change material is in asolid phase. When the container is exposed to the warmer environment,the phase change material absorbs heat during its phase change, keepingthe surrounding beverage at a cooler temperature over a longer period oftime as compared to the temperature of the beverage without use of thephase change material.

In another preferred embodiment, the cooling element is sized to fitwithin the open top of an unfinished container and the cooling elementhas features that allow the cooling element to be secured to the bottomor side of the container without use of an adhesive. In yet anotherembodiment of the present invention, the cooling element includes phasechange material encapsulated within a flexible plastic film pouch orbag, and the particular size and shape of the film covering can beadapted for use with many different types of containers.

One preferred type of phase change material includes a paraffin waxcompound having a phase change transition temperature at 6° C. The phasechange material is maintained in a solid state when the beverage ischilled below its melting temperature. When the container is removedfrom the chilled environment, the phase change material absorbs heatfrom the beverage within the container during the phase change therebymaintaining the temperature of the beverage cooler. While a paraffin waxtype phase change material is acceptable for use in the presentinvention, other phase change materials may be used to include other waxderivatives or hydrated solids. Further, phase change materials may beprovided in combinations wherein the respective melting pointtemperatures of the phase change materials are different. Accordingly,the cooling element provides cooling of the surrounding beverage over alonger period of time after the beverage continues to warm in responseto exposure to the warmer environment.

Preferably, the cooling element is relatively small and therefore doesnot materially affect the amount of beverage that can be placed withinstandard sized containers. The volume of the cooling element can becompensated for by slightly reducing the amount of headspace and/or thevolume of the beverage within the container.

As discussed further below, the cooling element may be secured to thebase of the container thereby minimizing the consumer's ability toobserve the cooling element. In some instances, a consumer may dislikeviewing the cooling element that otherwise distracts the consumer'sability to fully enjoy the beverage. The presence of the cooling elementmay be viewed as an undesirable foreign article in the beverage if itinterferes with the consumer's normal interaction with the container.

In yet another embodiment of the present invention, the cooling element,including the phase change material is attached externally to thecontainer. For a metallic can, the cooling element is preferably securedunder the container and attached to the dome. For a bottle, the coolingelement is also preferably secured to the bottom side of the containerin the concave gap formed at the base of the bottle.

In yet another embodiment of the present invention, it is contemplatedthat the thermal barrier liner may be used in combination withthermochromatic ink. In this combination, the thermochromatic inkprovides an indication of the temperature of the container viewable bythe consumer. In one preferred embodiment, the thermochromatic ink isprovided as a separate layer as compared to the thermal barrier liner.For example, the thermochromatic ink can be applied directly to theexterior surface of the container, and the thermal barrier liner is thenapplied over the thermochromatic ink layer. In another embodiment, it isthe thermal barrier liner that is secured directly to the externalsurface of the container, and the thermochromatic ink is applied overthe thermal barrier liner. In yet another embodiment, the thermalbarrier liner and thermochromatic ink are provided in a combined singlelayer.

In yet another aspect of the present invention, packaging is providedfor the container in which phase change materials are incorporatedbetween layers in the packaging in order to help maintain the containersat a desired temperature. In one preferred embodiment, the packagingcomprises a reusable container holder that has a plurality of openingsto receive containers therein. The reusable holder is made from, forexample, corrugated materials such as cardboard in which the phasechange material fills gaps between layers of the corrugated material. Inyet another embodiment, it is contemplated that the reusable containerholder may be constructed from a clear or translucent material, and thephase change material filling gaps between layers of the holder arecombined with thermochromatic ink. The thermochromatic ink can beselected to provide a pleasing visual appearance to the consumer, andthe thermochromatic ink also provides temperature indication therebyprompting the consumer to re-chill the container holder as necessary.

Other features and advantages of the present invention will becomeapparent from a review of the following detailed description, taken inconjunction with a review of the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a fragmentary perspective view of a beverage containerincorporating a thermal barrier liner of the present invention;

FIG. 2 is an enlarged fragmentary cross section view of the thermalbarrier liner of the present invention in a first embodimentcharacterized by a closed cell substrate layer or foam layer;

FIG. 3 is another enlarged fragmentary cross section of the embodimentof FIG. 2 showing the closed cell substrate layer after the containerhas been sealed and pressurized;

FIG. 4 is another enlarged fragmentary cross section view of the firstembodiment after the container has been opened resulting in expansion ofthe liner;

FIG. 4A is a greatly enlarged view of a portion of FIG. 4 showing thestructure of the substrate layer after the container has been opened;

FIG. 5 is an enlarged fragmentary cross section of a barrier liner inanother embodiment of the present invention comprising microcapsulescontaining encapsulated gas or liquid embedded in a base liner materialsealed and pressurized;

FIG. 5A is a greatly enlarged view of a portion of FIG. 5 showing thebarrier liner and the gas or liquid filled microcapsules;

FIG. 6 is a greatly enlarged view of the portion of FIG. 5 when liquidfilled microcapsules are used and undergo a phase change to a gas uponwarming and wherein the microcapsules expand in the gaseous state;

FIG. 7 is an enlarged fragmentary cross section view of a thermalbarrier liner in another embodiment of the present invention comprisingencapsulated solid phase change materials incorporated within a baseliner and showing the thermal barrier liner when the container is sealedand pressurized;

FIG. 7A is a greatly enlarged view of a portion of FIG. 7 showing thebarrier liner and the encapsulated solid phase change material withinthe microcapsules;

FIG. 8 is another greatly enlarged view of the embodiment of FIG. 7 whenthe container has been opened and the beverage has warmed to the phasechange temperature, showing the phase change material in themicrocapsules being in a liquid state after the phase change;

FIG. 9 is an enlarged fragmentary cross section view of anotherembodiment of the present invention illustrating a thermal barrier linerconstructed of a multi-layer configuration and illustrating thecontainer when sealed and pressurized;

FIG. 9A is a greatly enlarged view of the embodiment of FIG. 9 showingthe multi-layer configuration when the container is sealed andpressurized;

FIG. 10 is another greatly enlarged view of the embodiment of FIG. 9illustrating the container after it has been opened and expansion inthickness of the liner;

FIG. 11 illustrates yet another embodiment of the present invention inthe form of a composite thermal barrier liner including a combination offeatures of the prior embodiments including a closed cell substrate, andencapsulated gas and/or encapsulated phase change material set within abase liner;

FIG. 12 is a schematic view of equipment used to apply the thermalbarrier liner of the present invention as by spray coating;

FIG. 13 is a fragmentary perspective view of a container incorporating acooling element in accordance with the first embodiment of the presentinvention;

FIG. 14 is a plan view of the cooling element showing its relative sizewith respect to the diameter of the container and the manner in whichthe cooling element can engage the sidewalls of the container tomaintain the cooling element at a desired position within the container;

FIG. 15 is an enlarged cross section taken along line 3-3 of FIG. 2;

FIG. 16 is another fragmentary perspective view similar to FIG. 1, butillustrating the cooling element in a different configuration whereinthe cooling element conforms to the lower dome of the container;

FIG. 17 is a fragmentary perspective view of a cooling element inanother embodiment of the present invention wherein the phase changematerial is held within a flexible plastic film pouch;

FIG. 18 is a fragmentary perspective view of a container incorporating acooling element in accordance with another embodiment of the presentinvention wherein the cooling element more fully conforms to the bottomportion of the container;

FIG. 19 is perspective view of another cooling element in accordancewith another embodiment of the present invention;

FIG. 20 is a perspective view of yet another cooling element inaccordance with another embodiment of the present invention;

FIG. 21 is a perspective view of yet another cooling element inaccordance with another embodiment of the present invention;

FIG. 22 is a fragmentary perspective view of a container incorporating acooling element in accordance with another embodiment of the inventionwherein the cooling element is secured to the exterior bottom surface ofa can;

FIG. 23 is a another fragmentary perspective view of a containerincorporating a cooling element wherein the cooling element is securedto an exterior bottom surface of a bottle;

FIG. 24 is an enlarged cross-sectional view of a thermal barrier linerapplied to a container exterior surface, along with a layer ofthermochromatic ink that is placed between the container exteriorsurface and the thermal barrier liner;

FIG. 24 a is a greatly enlarged portion of FIG. 24 providing greaterdetails of the applied layers;

FIG. 25 is another cross-sectional view similar to FIG. 24; however thethermochromatic ink layer is applied over the thermal barrier liner;

FIG. 26 is yet another cross-section view similar to FIG. 24 showing athermal barrier liner applied to the exterior surface of the container,however the thermochromatic ink material is mixed directly within thethermal barrier layer thereby producing a composite thermal barrierliner incorporating a mixture of the thermochromatic ink;

FIG. 26 a is a greatly enlarged portion of FIG. 26 providing greaterdetails of the applied composite layer;

FIG. 27 is a perspective view of a container holder incorporating phasechange material for maintaining containers secured in the containerholder at a desired temperature;

FIG. 28 is a greatly enlarged fragmentary perspective view of thecontainer holder shown in FIG. 27, specifically showing the constructionof the container holder including gaps between the layers of thematerials making up the holder filled with phase change material, andoptionally also mixed with thermochromatic ink; and

FIG. 29 is a fragmentary cross-sectional view of a beverage holder inthe form of a beverage pitcher having a double walled construction withphase change material filling the gap between the walls.

DETAILED DESCRIPTION

With reference to the drawings, FIG. 1 shows a beverage container 10,particularly suited for beverages such as beer or carbonated softdrinks, fruit drinks, and like. The container is illustrated as aconventional beverage can having a sidewall or body 12, a base 14, andan openable top 16. The openable top 16 may include a closure mechanism,such as a pull-tab 17. The sidewall or body of the container isconstructed of conventional materials such as aluminum or steel. Theopenable closure mechanism 17 is also preferably aluminum or steel andmay include the pull-tab 17 that contacts a scored area 19 on the top16. Activation of the pull-tab 17 breaks the scored area 19 creating anopening or mouth to provide access to the beverage inside the container.As also shown in FIG. 1, the conventional container may include thebottom or base 14 having an annular lip 20 and a dome shaped panel 22.

In accordance with one embodiment of the present invention, a thermalbarrier liner 30 is provided as shown in FIGS. 1-4. The thermal barrierliner in this first embodiment comprises a gas permeable closed cellsubstrate 32. The substrate 32 is secured to the interior surface of thecontainer. The gas permeable closed cell substrate includes a pattern ofcells 34 defining a plurality of voids, gaps, or open spaces 36 therebyproviding the appearance of a foam layer. FIG. 2 illustrates thesubstrate 32 after the substrate has been applied to the interiorsurface of the container. As discussed further below, the substrate 32may be applied by spray coating. The voids or gaps may be of anirregular pattern and the voids or gaps may be of different sizes andshapes. In one aspect of the first embodiment, the thermal barrier linermaterial may be made from a homogenous material. In another aspect ofthis embodiment, the thermal barrier liner may include a combination ofmaterials. In either case, the liner is gas permeable and the cells 34have walls that are elastic/elastomeric such that the overall size ofeach of the voids/gaps 36 can change according to ambient pressureconditions.

The arrangement and size of the voids/gaps 36 may be a result of eitherhow the liner 30 is applied, and/or may be created during a curingprocess wherein the voids/gaps form over a period of time. The voidareas may be randomly dispersed and randomly sized. However, dependingupon the material used as the liner, a more orderly cellular pattern mayresult. The percentage of void or open cell space volume can rangebetween about 10 to about 95 percent of the overall volume of thethermal barrier liner.

One important attribute of the substrate 32 is that it be gas permeablesuch that when placed under pressure, the substrate will equilibrateresulting in a substantially uniform distribution of gas within thevoids 36. Furthermore, when pressure is reduced, the substrate shouldhave the capability to expand such that the cell walls 34 do not burst,tear, or otherwise degrade and, rather, will maintain an inflated statefor a period of time thus creating an effective thermal barrier linerrealized by the increased volume of the substrate 32.

It has been found through testing that some existing container linermaterials have the capability to be formed into foamed substrates andare elastic such that the substrate maintains integrity among variouspressure ranges. However, in order to create the closed cell substrateconfiguration and necessary gas permeability, foaming agents are addedto the liner materials. Two known liner materials may include Valspar9823-001, or ICI 640-C692CLS. When combined with the appropriate foamingagents, these liner materials may be applied to the interior surface ofthe container to form a thermal barrier liner having a gas permeableclosed cell substrate configuration that is able to equilibrate atworking pressure changes.

Referring to FIG. 3, this figure represents how the barrier liner 30appears when the container has been sealed and pressurized. As shown,the overall thickness of the barrier liner reduces in response to theincreased internal pressure within the container. Accordingly, FIG. 2shows a thickness “a” of the liner that may be somewhat larger than thethickness “b” of the liner when the container is sealed and pressurized.For carbonated beverages, carbon dioxide is the primary gas that fillsthe container under pressure. Accordingly, the substrate must bepermeable to allow passage of the carbon dioxide if used with suchcarbonated beverages. Within a period of time, the thermal barrier linerwill allow passage of the pressurized gas within the container such thatthe substrate is fully entrained with the pressurized gas. Optionally,liquid nitrogen may be added to the beverage just before sealing toassist in pressure development. In most container filling processes, theend or cap of the container is not attached to the body of the containeruntil the beverage has been added to the container. When the end or capis attached, a seal is created thus preventing liquid or gas fromescaping. Pressure within the container will increase due to a number offactors such as carbonization within the beverage, any added liquid suchas nitrogen that will transition to a gas phase, and pasteurization ofthe beverage by heat treatment. As the thermal barrier liner becomesentrained with the gas, the liner will de-compress as it equilibrateswith the internal gas pressure, some reduction in the area of theheadspace of the container may occur by thickening of the liner due toentrainment of the pressurized gas into the liner after the containerhas been sealed and pressurized. However, normal levels of containerpressurization do not have to be significantly altered to account forpresence of the liner since the liner even in its fully gas entrainedstate after sealing and pressurization takes up a minimum volume withinthe container.

The thermal barrier liner is preferably of a thickness under ambientpressure conditions such that it does not unduly displace the typicalamount of the beverage within the container. Thus when the barrier linerexpands under ambient pressure conditions, the beverage in the containerwill not be forced through the opening in the container.

Referring to FIG. 4, this figure represents the point in time when thecontainer has been opened. In response to the reduction in ambientpressure, the cells 34 expand in size to reach equilibrium. Thus, thethickness “c” of the liner is greater than both the thicknesses “a” and“b”. The cells maintain this expanded state for a period of time thusproviding an effective thermal barrier liner to maintain the beverage ata desired temperature. Typically, the pressure within the containerprior to opening is 10 to 35 psi, depending upon carbon dioxide andnitrogen levels and temperature of the beverage. By expanding theoverall thickness of the barrier liner 30, and without otherwisealtering the dimensions of the container or any other parameters, thethermal barrier liner is enhanced simply by the ambient pressure changesbetween the unopened and opened container.

An added benefit with respect to this embodiment is that when thecontainer is being chilled (when unopened) fast chilling of the beveragemay take place since the thermal barrier liner is in its more compressedor thin state, thereby allowing rapid heat transfer away from thecontainer without having to overcome a relatively thickened insulatingmember.

The permeability of the thermal barrier liner is such that gas isallowed to permeate through the cell walls over a period when underpressure to reach equilibrium, for example, a few hours, but the cellwalls are not so permeable that immediate deflation takes place whenambient pressure is reduced. Therefore, the thermal barrier liner willmaintain a full thickness for at least a period of time in which aconsumer would normally consume the beverage. It is contemplated that itmay take up to twenty-four hours for pressurized gas within thecontainer when the container is sealed to permeate through the thermalbarrier liner but when the container is opened, it will take at leastone hour before the thermal barrier liner reaches equilibrium with thereduced pressure of the environment. Thus, a full, thickened barrierliner is maintained during the time period in which a consumer normallyconsumes the beverage.

FIGS. 5, 5A and 6 illustrate another embodiment of the present inventionin the form of a thermal barrier liner 30 comprising a layer of basematerial 42 interspersed with an additive component 40 such as gas orliquid filled microcapsules. The base material 42 binds to the additivecomponent 40 and ensures a continuous coating of the interior surface ofthe container.

The additive component 40 can either be a majority component or minoritycomponent by volume as compared to the base layer 42. As mentionedfurther below with respect to a method of applying the thermal barrierliner, the base material 42 and additive component 40 may be premixedinto a single slurry and spray coated onto the interior surface of thecontainer.

Preferably, the additive component is dispersed randomly throughout thebase layer. Once the interior of the container is coated with thebarrier liner, it is cured to optimize the thermal barrier properties.For example, the container can be oven dried to evaporate and otherwiseremove any solvents or other substances used with the additive componentduring application to the container. This curing process can also beused to condition gas filled microcapsules. For example, heat applied tothe container during curing can cause a controlled amount of expansionof the gas filled microcapsules so that the barrier liner is placed in adesired state prior to filling of the container.

One example of an additive component that may be used as amicroencapsulated gas includes Expancel®. Expancel® is a commerciallyavailable product that includes elastic micro-spheres or microcapsules,roughly ten micrometers in diameter, filled with a small amount ofliquid hydrocarbon. When heated within a known temperature range, thehydrocarbon liquid vaporizes to a gas state within the micro-spheres.The shells or casings of the micro-spheres expand as the gas expandswithin the micro-spheres. In the expanded state, the micro-spheres canexpand to a diameter of four times the un-expanded state resulting in avolume increase of approximately forty times larger than the un-expandedsize. The micro-spheres can be used either in an unexpanded state or apre-expanded gaseous state, depending on application capabilities andthe elasticity of the base material 42. With respect to use as aninsulation material in the present invention, use of pre-expandedspheres for the additive component 40 would create a pattern of voids inthe base layer.

As mentioned, the microcapsules create voids in the base layer andthereby enhance the thermal barrier capability of the liner. The sizeand distribution of the voids created by the gas or liquid filledspheres can be selected to provide the desired level of insulation forthe container. A greater concentration of micro spheres will producemore voids. The particular gas or liquid selected can be selected tooptimize the desired level of insulation.

In the event that the liner is applied to the interior of the containeras by spray coating, one option is to activate the microspheres to theirexpanded state when the liner is cured. A drying oven can be used tocure the liner and the heat from the oven would result in activation ofthe microspheres to create the insulating voids.

It is also contemplated that liquid filled micro spheres can be providedso that the liquid changes phase to a gaseous state when the beveragewarms during consumption by the consumer. Thus, when the beverage ismaintained in its cooled state during storage, the micro-spheres wouldremain in a liquid state. Referring to FIG. 6, when the container isopened and exposed to the warmer environment, the increase intemperature causes the micro-spheres to transition to a larger diameteras the liquid changes phase to the gas state. Thus, the expansion of thethermal barrier liner in this example is activated by temperature andnot by ambient pressure changes. A liquid-gas phase change property forthe thermal barrier liner of the present invention may be particularlysuited for containers that are not pressurized, such as juice, fruit, orvegetable containers.

For both the first and second embodiments, one acceptable base linermaterial 42 may include Valspar 9823-001 or ICI 640-C692CLS. Increasedcuring times may be required depending upon the addition of an additivecomponent which may, therefore, increase the curing time.

Now referring to FIGS. 7, 7A and 8, in another embodiment of the presentinvention, a thermal barrier liner is provided comprising a base layer42, and an additive component 40 in the form of encapsulated phasechange material. The encapsulated phase change material 50 may also bemicrocapsules that are interspersed as shown within the base layer 42.One example of phase change material that may be used includesparaffinic hydrocarbons. Another phase change material may includehydrated salts. One commercially available type of phase change materialmay include MPCM-6, a product sold by MicroTek Laboratories, Inc. MPCM-6is a microencapsulated paraffin wax (specific latent heat of 188.6 J/g)in a polymer shell with a solid to liquid phase change temperatureoccurring at 6° C. When chilled to below 6° C., the paraffin exists as asolid. As the spheres absorb heat, the encapsulated paraffin rises intemperature until it reaches 6° C. At that temperature, the paraffincontinues to absorb heat, but stays at a relatively constant temperatureuntil it has completely transitioned from a solid to a liquid phase. Theheat absorbed by the phase change material, also known as latent heat,would otherwise have caused an increase in the temperature of thebeverage within the container. The total amount of heat capable of beingabsorbed by the paraffin wax can be calculated and adjusted by varyingthe amount of paraffin used within the barrier layer. For example, 25 ccof MPCM-6, which would normally require a minimum liner thickness of onemillimeter, absorbs the equivalent heat that would otherwise cause a 5°F. increase in temperature of a 355 cc beverage.

FIGS. 7 and 7A specifically illustrate this third embodiment wherein thecontainer is under pressure and assumedly at a chilled temperature (forexample below 6° C.). FIG. 8 shows the container when removed fromrefrigeration and warmed to a temperature wherein the solid phase changematerial has transitioned from a solid to liquid state. Morespecifically, the materials in the microcapsules 50 are shown in FIGS. 7and 8 as transitioning from a solid state 51 to a liquid state 52.

FIGS. 9, 9A and 10 illustrate yet another preferred embodiment of thepresent invention. In this embodiment, the thermal barrier liner 30comprises multiple layers 60 of a lining material wherein voids or gaps62 exist between each of the layers. The voids or gaps between thelayers may be provided in an irregular pattern. Thus, the layers do notlie evenly over one another and the layers extend non-linearly havingcontinuous patterns of bends or curves in the liner material that formthe voids or gaps 62. As shown in FIGS. 9 and 9A, when the container isunder pressure and unopened, the layers 60 form a more compressed,thinner profile. However, as shown in FIG. 10, when the container isopened and ambient pressure is reduced, the gas trapped in the voidsbetween the layers results in an expansion of the liner, therebyenhancing thermal barrier properties of the liner.

This multi-layer liner can be constructed of multiple layers of the samematerial, or may be made of dissimilar materials. With respect to asingle material used, if the single material is applied at differenttimes with different temperatures or viscosities, voids or gas pocketsmay be formed between layers. With respect to use of dissimilarmaterials, void areas between the layers may be formed more as afunction of the ability of layers to adhere to one another, among otherfactors. Unlike conventional liners applied to the interior ofcontainers, it is the intent in the embodiment shown in FIGS. 9 and 10to apply a multi-layered liner wherein intentional voids or gaps arecreated between the layers of material such that gases may be trappedbetween the layers. Thus, as mentioned above, the variation oftemperatures, viscosities, as well as use of dissimilar materials canresult in the creation of a multi-layered liner having inconsistenciesin how the layers adhere to one another. Visually, the liner of thisembodiment may appear somewhat wrinkled or may appear as having aroughened surface. These apparent inconsistencies in the liner are aresult of the intention to provide gaps or void spaces between thelayers of the liner. Thus, this multi-layered liner significantlydeparts from multi-layered liners, either used internally or externallyfor containers, wherein the failure to completely adhere one layer toanother may be considered a significant defect.

Referring to FIG. 11, a composite thermal barrier liner may be providedby combining one or more of the attributes from the prior embodiments.More specifically, FIG. 11 illustrates a gas permeable closed cellsubstrate 32 being formed, as well as microencapsulated gas and/ormicroencapsulated solid-liquid phase change material 40/50 being setwithin a base layer 42.

Referring to FIG. 12, one method by which the thermal barrier liner maybe applied to a container is by spray coating. Accordingly, FIG. 12illustrates a spray coating device 70 positioned to apply a coating ofmaterial to form the thermal barrier liner. The spray coating device 70may be conventional, as found in many container manufacturing lines.Accordingly, the coating device may include a nozzle 72 that directs anatomized spray 74 that forms the barrier liner 30. The containers can berotated in the range of the spray 74 in order to ensure a uniform layeris applied to the container. The atomized spray can be pressurized andcan also be airless meaning that the liquid spray does not require apressurized entrained gas to deliver the spray. Since the barrier liner30 is applied by spray coating, both the sidewalls and interior base ofthe container may be coated. With respect to the multi-layer embodimentillustrated in FIGS. 9, 9A and 10, a plurality of layers may be appliedby separate spray coating steps, for example, a first coat is applied bya first spray coating device, and then additional layers are provided byother spray coating devices incorporated in series within the productionline. As mentioned above, various temperatures and materials can be usedto create the desired gap/void arrangement between the layers ofmaterials.

Although spray coating the liner has been described as a preferredmethod of installing the liner, it is also contemplated within thepresent invention that a number of other manufacturing techniques may beused to incorporate the thermal barrier liner into the presentinvention. For example, the thermal barrier liner may be pre-made andthen mechanically inserted within the container, or the interior linerof the container may be coated by contact with processing equipment thatdispenses the thermal barrier liner and adheres or seals the liner tothe interior of the container. Additionally, while spray coating may beadvantageous for applying the liner to both the interior sidewall andinterior surface of the base of the container, application of the linerto the base is optional. Further, while it may be advantageous to notrequire use of an adhesive to secure the thermal barrier liner to theinterior of the container, such as when a spray coating process is used,in some liner installation techniques it may be advantageous to use someamount of adhesive.

With respect to a preferred thickness of the thermal barrier liner, itshall be understood that none of the embodiments are strictly limited toa specific range but it has been found that a liner between about 1.0 mmto 3.0 mm provides adequate insulation without displacing a quantity ofthe beverage that adversely affects desired headspace within thecontainer. For the first embodiment, the thermal barrier liner can bebetween about 0.5 mm and 1.5 mm in thickness when the container issealed and pressurized, and the thermal barrier liner expands to betweenabout 1.0 mm and 3.0 mm when the container is opened and exposed to theenvironment.

For each of the embodiments of the present invention, it shall beunderstood that the thermal barrier liner 30 may be used as anadditional layer applied to the interior surface of the containerstrictly for purposes of insulation, or may also serve as a combinationof a conventional interior liner of the container to prevent undesirablecontact between the beverage and the metallic sidewall and base, as wellas a thermal insulating barrier. In order to improve adhesion of theliner to the sidewall of the container, a primer layer could be appliedprior to applying the liner. Also, in order to create the liner havingan adequate thickness, the spray coating may include two separateapplications or passes wherein after the first coat or layer is applied,the container is air dried prior to applying the second layer. Thecontainer could then be dried/cured to complete the liner applicationprocess.

It shall be understood that the thermal barrier liner of the presentinvention significantly departs from traditional liners used to coat theinterior of a container for purposes of preventing spoilage of thebeverage in the container. More specifically, conventional liners areformed to create a very smooth, thin, and non-insulative layer. Thus,the thermal barrier liner of the present invention by provision of aclosed cell substrate, and/or with micro-encapsulated materials, or amulti-layer liner provides a unique solution for a thermal barrier, yetat the same time still fulfills the need for providing a liner toprevent direct contact of the beverage with the metallic sidewall andbase of the container.

As also mentioned above, provision of a gas permeable liner that canequilibrate between different ambient pressures allows creation of athicker insulative layer once the container is opened. Providing thisactive or size changing barrier liner also has the benefit of allowingthe container to be more easily cooled when unopened, yet allowssubstantially the same amount of beverage to be maintained in thecontainer since the barrier liner occupies a minimum volume when underpressure or when chilled.

With respect to the embodiment of the present invention providing amulti-layered liner, the structure here is intended to provide voidsbetween layers as opposed to material protective liners in which theintent is primarily to minimize void areas between the layers in orderto maximize the bond between the layers. In fact, many can linersrequire additives therefore improving the wetting or contact area tomaximize bonding between the layers. However, with the presentinvention, the bonding areas between the layers is reduced to the pointwhere a balance can be achieved between a bond strength such that thelayers maintain integrity and remain bound to one another, yet gaps orvoid areas are formed to allow permeation of gas and subsequentexpansion thereby creating an effective thermal barrier liner. Sometechniques to promote rough and irregular surface bonding between thelayers may include use of high viscosity materials, cold applicationtemperatures, and use of different materials between layers that are notfully miscible.

While the preferred embodiments of the present invention have been shownspecifically with respect to a traditional aluminum or steel container,it shall be understood that the thermal barrier liners of the presentinvention can be incorporated within any type of container to includeplastic containers such as PET bottles, or conventional aluminum orsteel cans used to contain fruits, vegetables, soups, meat or otherproducts.

Because the thermal barrier liner of the present invention is preferablyformed with a liner material having some adhesive characteristic, it isunnecessary to provide a separate adhesive coating or layer in order tosecure the thermal barrier liner to the interior surface of thecontainer. Furthermore, as discussed above, the thermal barrier liner ofthe present invention may be used in addition to or to replace thetraditional can liner used for purposes of preventing direct contactbetween the beverage and the interior surface of the container.

While the present invention has been discussed for use in keepingbeverages cool, it shall also be understood that the present inventioncan also be used to thermally insulate a beverage intended to be servedat room temperature or warmer. For the first embodiment of the presentinvention incorporating the closed cell substrate that is capable ofthermally insulating a container by only changes in pressure, thisembodiment can certainly be used for those beverages that are intendedto be served at room temperature or warmer.

The automatic activation of the thermal barrier liner under variablepressure or temperature conditions makes the thermal barrier liner idealin those commercial applications where the beverages may be stored underpressure, such as the case for carbonated soft drinks and beer.

Because the thermal barrier liner of the present invention may beapplied using manufacturing techniques such as spray coating, it isunnecessary to significantly alter or otherwise modify known beveragepackaging machinery or processes.

Referring to FIG. 13, a beverage container 110, particularly suited forbeverages such as beer or carbonated soft drinks, is shown. Thecontainer is illustrated as a conventional beverage can having asidewall or body 112, a base 114, and an openable top 116. The openabletop 116 may include a closure mechanism, such as a pull-tab 117. Thesidewall or body of the container is constructed of conventionalmaterial such as aluminum or steel. The closure mechanism 117 is alsopreferably aluminum or steel and may include the pull-tab 117 thatcontacts a scored area 119 on the top 116. Activation of the pull-tabbreaks the scored area creating an opening or mouth to provide access tothe beverage inside the container. As also shown in FIG. 13, the base114 may have an annular lip 120 and a dome shaped panel 122. Aperipheral concave or curved area 126 resides between the lip 120 andthe cylindrical sidewall.

In accordance with another embodiment of the present invention and alsoreferring to FIGS. 14 and 15, the container incorporates a coolingelement 130. The cooling element has an outer shell 131 or covering thatencapsulates a quantity of phase change material 148 therein. As shownin these figures, the shell is very thin thereby minimizing any thermalinsulation properties that would inhibit absorption of heat by the phasechange material when the container is exposed to the warmer environment.In this first embodiment, the shape or configuration of the coolingelement is provided such that it can be placed at a selected locationwithin the container and maintained at that location without therequirement to use an adhesive to secure the element. The coolingelement has a low profile defined by a very small thickness as comparedto the overall height of the container. Thus, the cooling element is avery non-obtrusive element that does not interfere with the normal flowof beverage from the container when the beverage is consumed. This lowprofile also makes the cooling element more difficult to view by theconsumer when the cooling element is secured adjacent to or in the baseof the container thereby limiting any distractions that could beassociated with the viewing of the cooling element.

As shown in FIGS. 14 and 15, the cooling element 130 has a disc shapedbody with an upper surface 134, a lower surface 136, and a peripheraledge 138. Extending from the peripheral edge 138 are a plurality of finsor extensions 140 that make contact with the interior surface 124 of thesidewall 112. In this embodiment, the lower surface 136 also preferablymaintains contact with the interior surface of the dome 122. Theextensions 140 are preferably made of the same material as the outershell, and are flexible and resilient such that the extensions 140maintain frictional contact with the interior surface 124. One preferredshape for the extensions are shown as curved members having pointeddistal tips 144 and enlarged base portions 142 that connect to the bodyof the cooling element.

During production, the cooling element 130 may be installed by acylindrical shaped mandrel (not shown). The mandrel may be insertedwithin the open top of the container. When the mandrel is removed, thespring action of the extensions 140 keeps the cooling element in placewithin the container by frictional engagement of the extensions 140against the interior surface 124 of the sidewall.

While the fin shaped extensions are shown in this particular embodiment,it shall be understood that other shaped extensions may be provided toachieve the same purpose, namely, maintaining frictional engagement withthe interior surface of the container thereby holding the widget inplace without the requirement for use of an adhesive.

Referring to FIG. 15, the phase change material 148 fills the body.However, the fin shaped extensions 140 preferably do not have phasechange material therein.

Referring to FIG. 16, a slightly different configuration is provided forthe cooling element of the first embodiment wherein the cooling element130′ has a curved shape body that conforms to the dome shaped panel 122.The fin shaped extensions, however, still extend away from the body sothat they extend substantially orthogonal or perpendicular with respectto the sidewall of the container.

Referring to FIG. 17, another embodiment of the present invention isillustrated wherein a cooling element 150 is a pouch or pocket havingphase change material 148 therein. More specifically, the coolingelement 150 may include an upper surface 156 formed from a first sheetof flexible plastic film and a lower surface 158 made from a secondsheet of flexible plastic film. The two sheets of film material aresealed to one another along an exterior edge 154 of the pouch. In FIG.17, a substantially rectangular shaped pouch is shown. However, it shallbe understood that the pouch may be configured in many different shapesto include round, or even a donut shaped pouch that frictionally engagesthe sidewalls of the container. In this second embodiment, the use of aflexible pouch containing the phase change material is very adaptablefor placement into many different types and shapes of containers. Thepouch may be shaped and sized to best accommodate the type of containerthat is to receive the cooling element.

Referring to FIG. 18, another embodiment is illustrated wherein acooling element 160 more fully conforms to the dome shaped panel 122 ofthe base 114. As shown, the cooling element 160 has a generally flatupper surface and a curved lower surface in contact with the dome shapedpanel. The curved peripheral edge 166 of the cooling element generallyconforms to the lip 120. With this nested arrangement of the coolingelement 160, the cooling element conveniently rests on the dome shapedpanel and, is prevented from freely shifting within the container. Aswith the prior embodiments, the cooling element 160 contains a desiredphase change material therein.

Referring to FIG. 19, another configuration for a cooling element isshown in the form of a cooling element assembly 170. This assembly 170comprises a plurality of individual cooling elements 172 set within asupporting frame. As shown, the individual cooling elements 172 areseparated from one another by radial arms 174 of the frame that extendsfrom a central area 173. The peripheral edge 176 of the frame is sizedto frictionally engage the interior sidewall of the container. Each ofthe cooling elements 172 has an exterior shell with encapsulated phasechange material therein. Although this figure shows a cooling elementresiding in each gap between arms 174 of the frame, it shall beunderstood that a selected level of cooling may be obtained by simplychoosing the number of cooling elements to be incorporated in thecooling element assembly. The frame having a continuous peripheral edgeas well as the radial arms or spokes helps to create sufficient rigidityfor the cooling element assembly so that it does not randomly shiftwithin the container.

Referring to FIG. 20, another cooling element 180 is shown wherein thecooling element has an irregular shaped body 184 characterized byruffled or uneven surfaces. A peripheral edge 182 of the cooling elementforms a generally circular closed shape. This cooling element 180 can besized so that at least some portions of the peripheral edge 182 contactthe interior surface of the container thereby frictionally holding thecooling element in place. As with the other embodiments, an outer shellor covering of the cooling element houses a quantity of phase changematerial therein.

Referring to FIG. 21, yet another cooling element 190 is shown whereinthe cooling element has a disc shaped body 192 sized to fit within thedesired container. Accordingly, the peripheral edge 194 frictionallyengages the interior surface of the container sidewall. The coolingelement 190 also has an outer shell that houses a quantity of phasechange material therein.

Referring to FIG. 22, another embodiment is shown in which a coolingelement 200 is secured to the exterior of the container. Morespecifically, FIG. 22 illustrates a cooling element 200 that is securedto the exterior bottom side of the container 110, and the coolingelement 200 conforms to the shape of the dome 122. Preferably, thethickness of the cooling element 200 is such that it does not protrudedownward below the annular lip 120. Accordingly, the container 110 maystill be placed on a flat surface in a steady manner, and the container110 may be stacked on top of another container without substantialinterference by the presence of the cooling element 200. The coolingelement 200 may be constructed the same as the cooling elements in theother embodiments, namely, the cooling element has an outer shell orcovering that encapsulates a quantity of phase change material therein.However, for the embodiment in FIG. 22, it may be desirable to providethe exposed lower surface of the cooling element 200 with a stiffermaterial to prevent breakage of the shell. For example, a selectedthermoplastic having sufficient rigidity may be appropriate for manycontainers.

Referring to FIG. 23, another embodiment is illustrated in which acontainer 210 in the form of a glass container or bottle incorporatesthe cooling element 200. The bottle 210 is conventional, includingvertical sidewalls 212, and a concave depression 214 formed at thebottom end thereof. Typically, the concave depression in a bottle is notas pronounced as the dome of a metal container. Therefore, a smallercooling element 200 would be required in order to avoid the coolingelement 200 protruding below the bottom annular area 216 of thecontainer. The construction of the cooling element in FIG. 23 may be thesame as described with respect to FIG. 22, including an exposed lowersurface for the cooling element that may be relatively rigid in order toprevent inadvertent breakage of the cooling element.

Referring to FIGS. 24 and 24 a, in yet another embodiment of the presentinvention, a thermal barrier liner 224 is applied over the exteriorsurface 220 of a container. The exterior surface 220 may be glass,plastic, metal, or any other material which may be used as a container.In the embodiment of FIG. 24, the thermal barrier liner may be the sameas illustrated and described with respect to FIG. 7, namely a barrierliner that includes micro encapsulated phase change material shown inFIG. 24 a as microcapsules 228 set within a base material 226. The basematerial could be, for example, a varnish material. In addition to thethermal barrier layer 224, an additional layer is illustrated, namely athermochromatic ink layer 222. Thermochromatic or thermochromic inks ordyes are those chemical formulations that display color changes overspecific temperature ranges. These inks or dyes may be manipulated todisplay desired colors over critical temperature ranges.Microencapsulation techniques have been developed to enable the use ofthermochromatic inks to be applied in various printing processes. Thethermochromatic pigments forming the thermochromatic ink are reversiblein their color change such that a visible change in color occurs inresponse to a change in temperature, and the color change then reversesback to the original color when the temperature surrounding thethermochromatic ink returns to its original temperature.

One example of an acceptable thermochromatic ink that can be used in thepresent inventions includes those disclosed in the U.S. Pat. No.5,997,849, this reference being incorporated by reference for purposesof disclosing possible thermochromatic ink formulations.

One advantage of incorporating the thermochromatic ink layer in theinvention shown in FIG. 24 would be to allow a consumer to view thetemperature state of the beverage within the container. Further, thethermochromatic ink could be used for purposes of enhancing the visualappearance of container graphics, and to otherwise supplement a desiredpresentation of the beverage at various temperatures.

Referring to FIG. 25, yet another cross-section is shown of a containerthat incorporates both a thermal barrier liner as well as athermochromatic ink layer. In FIG. 25, instead of the thermal ink layerbeing disposed between the barrier liner and exterior surface of thecontainer, the thermochromatic ink layer 222 is applied over the thermalbarrier liner/layer 224. Therefore, the thermochromatic layer 222 isexposed. Placing the thermochromatic layer 222 as the exposed layer maybe advantageous and some packaging considerations, including the use ofsome labels that may be placed over the container in which thethermochromatic layer may be more easily viewed by a consumer inconjunction with graphics contained on the label. For example, a label(not shown) applied over the ink layer 222 may have gaps or holes whichexpose the thermochromatic layer in order to enable a consumer to viewthe temperature characteristics of the beverage. Further, the labelitself may be constructed of a material which enables the color of thethermochromatic ink layer to react with colors within the label toprovide a desirable visual effect for the consumer. For example, atranslucent or clear label with graphics incorporated thereon may moreeasily allow the color characteristics of the ink layer to be viewed bya consumer.

Referring to FIGS. 26 and 26 a, yet another embodiment is shown of acomposite thermal barrier layer 224, which incorporates encapsulatedphase change material 229, and further where a thermochromaticformulation 230 is directly incorporated in the thermal barrier layer224. Accordingly, FIG. 26 is intended to represent a thermal barrierlayer 224 having a composite mixture in which the thermochromatic dyesare mixed with the base layer 226. FIG. 26 illustrates thethermochromatic dyes as small discrete elements 230, but it should beunderstood that the character of the thermochromatic dyes can be suchthat the base material 226 and thermochromatic dyes form a substantiallyhomogeneous mixture.

Referring to FIGS. 27 and 28, yet another embodiment of the invention isshown in the form of container holder 240, that is especially adaptedfor holding one or more containers 110 prior to serving the same toconsumers. The container holder 240 may therefore be used as anintermediate container storage device that is intended to maintainbeverages at a desired temperature just prior to serving the beverage toa consumer. Establishments such as bars or restaurants would be likelycandidates for use of the holder, or vendors at entertainment orsporting events could also utilize the holder 240. Structurally, theholder is characterized by a plurality of enclosing sidewalls 242, anupper surface 244 and a lower surface 246. A plurality of cavitiesdefined by shaped interior walls 248 and integral bottom surfaces 250receive one or more containers 110. The holder 240 can be adapted toreceive various shaped containers by modifying the shapes of the walls248 and bottom surfaces 250. Referring to FIG. 28, further structuraldetails are shown in which gaps or spaces 252 are found between thecavities and the enclosing sidewalls 242 and lower surface 246. Thesegaps are filled with phase change materials, such as microencapsulatedphase change materials set within a base material. The microencapsulatedphase change and base materials can be the same as described withrespect to the embodiment of FIGS. 24 or FIG. 26. During construction ofthe holder 240, the selected base material may be in a heated liquidform which has the microencapsulated phase change materials therein. Theheated liquid could be injected in the gaps 252. The heated liquid wouldthen cool to a solid, forming a substantially rigid thermal barrierstructure filling the gaps 252.

The holder 240 is preferably reusable. Once the beverages have beendistributed from the container holder, the holder may then be returnedto a refrigerator/freezer to again cool the phase change material belowits threshold phase change temperature. Once cooled, the containerholder is then ready for re-use to cool beverage containers.

For the embodiment of FIGS. 27 and 28, it is contemplated that twoholders 240 could be used in a clam-shell configuration. That is, oneholder 240 holds the lower half or part of a beverage, and anotherholder 240 covers the upper portion or halves of the container.Therefore, in this clam shell arrangement, a pair of holders 240 couldbe used to completely cover the containers prior to distribution to aconsumer.

Although FIGS. 27 and 28 illustrate a holder 240 having a plurality ofcompartments or cavities to receive multiple beverages, it is alsocontemplated that a temperature controlled holder could directly receivea beverage. Accordingly, referring to FIG. 29, a double walled pitcher260 is provided in which phase change materials set within a basematerial fills the space 270 between the double walled pitcher. Thepitcher has a handle 262, a pour spout 263, and a base 266. Morespecifically, FIG. 29 shows the pitcher 260 having an interior wall 268and an exterior wall 264 spaced from the interior wall 268 by the gap270. The phase change material and base material are sealed between theinterior and exterior walls enabling the pitcher to be re-used.

In each of the embodiments of the present invention, it is contemplatedthat one or more phase change materials may be used to maintain coolingfor the particular beverage. For beverages that may take a consumerlonger to consume, it may be beneficial to provide two or more differenttypes of phase change material wherein the phase change for eachmaterial occurs at different temperatures so as the beverage continuesto warm, the different phase change materials absorb heat over a greaterrange of temperatures and over a greater period of time.

One commercially available manufacturer of phase change materials isMicroTek Laboratories, Inc. of East River Road, Dayton, Ohio. Asmentioned above, two acceptable types of phase change materials mayinclude various paraffin complexes, as well as hydrated salts.

One particular phase change material sold by MicroTek Laboratories, Inc.is MPCM. MPCM is an encapsulated paraffin wax (heat capacity of 188.6J/g) in a polymer shell with a solid to liquid phase change temperatureof 6° C. When chilled to below 6° C., the paraffin exists as a solid. Asthe encapsulated paraffin wax absorbs heat, the paraffin wax rises intemperature until it reaches 6° C. At that temperature, the paraffin waxcontinues to absorb heat but stays at a relatively constant temperatureuntil it has completely transitioned from a solid to a liquid phase. Theheat absorbed by the phase change (latent heat) helps to maintain thebeverage at a cooler temperature.

The total amount of heat required to be absorbed in order to maintainthe beverage at a desired chilled temperature can be calculated andadjusted based upon the amount of phase change material being used. Inthis example, 25 cc of MPCM absorbs the equivalent heat that wouldotherwise cause a 5° F. increase in the temperature of a 355 ccbeverage.

The cooling element in the embodiments is preferably relatively smalland therefore does not materially affect the amount of beverage that canbe placed within standard sized containers. As mentioned, the volume ofthe cooling element can be compensated for by slightly reducing theamount of headspace and/or the volume of the beverage within thecontainer. As also mentioned, some of the preferred embodiments securethe cooling element to the base of the container thereby minimizing theconsumer's ability to observe the cooling element and thereforeminimizing any distractions a consumer may associate with the presenceof the cooling element.

While the present invention has been disclosed above with respect tocooling elements having particular size or configuration, it shall beunderstood that other shapes and sizes of the cooling elements can beprovided, the only relevant limitation being that the cooling elementshould be large enough to prevent the widget from passing through thecontainer opening. Thus, while it may be preferable to provide a widgetthat frictionally engages the sidewalls or base of the container, it isalso contemplated that the widget could be free floating within acontainer. Depending upon the density of the widget, it could thereforeeither float near the surface of the beverage or sink to the base.

In each of the embodiments of the present invention, it is alsoimportant to use materials that are compatible with the particularbeverage and container such that there are no adverse chemical reactionsthat take place including reactions or mere exposure that may alter theflavor of the beverage. Further, in the event that the outer protectiveshell or covering of the cooling element breaks or is otherwisecompromised, it is also important to make use of phase change materialthat is also non-toxic and cannot harm the consumer. It is alsodesirable to provide a shell or casing material that is non-reactivewith the beverage, and is also a barrier that prevents migration ofphase change material into the beverage, and vise versa. Thus, the shellmaterial should be non-permeable with respect to the beverage in thecontainer.

While the preferred embodiments of the present invention have been shownspecifically with respect to a traditional aluminum or steel container,it shall be understood that the cooling element can be incorporatedwithin any type of container to include plastic containers, such as PETbottles or conventional aluminum or steel cans used to contain otherproducts such as juices, fruits and vegetables.

While the present invention has been described with respect to variouspreferred embodiments, it shall be understood that various other changesand modifications to the invention may be made, commensurate with thescope of the claims appended hereto.

What is claimed is:
 1. An insulated beverage container comprising: asidewall, a base connected to the sidewall and a top forming an upperportion of the container; a thermal barrier liner applied to an exteriorsurface of said sidewall, said thermal barrier liner comprising a basematerial and a plurality of microcapsules dispersed in said basematerial, said microcapsules containing phase change material therein,wherein the phase change material absorbs heat from a beverage withinthe container, and the phase change material changes phase from solid toliquid upon absorbing the heat; a thermochromatic layer disposed eitherbetween the exterior surface of the container and the thermal barrierliner, or disposed above the thermal barrier liner attached directly tothe exterior surface of the container, thereby exposing saidthermochromatic layer; said thermochromatic layer including aformulation of a thermochromatic material formed of micro capsules eachcontaining reversible coloring agents that exhibit a visible change incolor between a first color state and a second color state in responseto a change in temperature.
 2. The container, as claimed in claim 1,wherein: said thermal barrier liner is substantially transparent ortranslucent enabling a consumer to view color changes of saidthermochromatic layer.
 3. The container as claimed in claim 1, wherein:said base material is made of a thermoplastic material that is elastic.4. The container as claimed in claim 1, wherein: said base material ismade of a varnish material.
 5. The container as claimed in claim 1,wherein said thermal barrier liner is made of a material that iselastic.
 6. An insulated beverage container comprising: a sidewall, abase connected to the sidewall and a top forming an upper portion of thecontainer; a thermal barrier liner applied to an exterior surface ofsaid sidewall, said thermal barrier liner comprising a base material anda plurality of microcapsules dispersed in said base material, saidmicrocapsules containing phase change material therein, wherein thephase change material absorbs heat from a beverage within the container,and the phase change material changes phase from solid to liquid uponabsorbing the heat; and a thermochromatic material incorporated directlywithin said thermal barrier liner, said thermochromatic materialincluding micro capsules each containing reversible thermochromaticcoloring materials that exhibit a visible change in material between afirst color state and a second color state in response to a change intemperature.